Releasing carrier with transfer coating for decorative laminates

Abstract

A temporary support with a transferable film composition coated on its surface is used in the manufacture of heat and pressure consolidated laminates to produce laminates of improved surface strength and functional properties. The film is composed of polyvinyl butyral resin and melamine resin. Additives may be included in the film composition for functional purposes and appearance.

What is claimed is: 
     
       1. A releasing carrier having on its surface a transferable film composition that is capable of transferring to and reacting with noble thermosetting resin impregnants of decorative fibrous sheets in a heat and pressure laminating process wherein the film composition is comprised of polyvinyl butyral resin and melamine resin. 
     
     
       2. The releasing carrier according to claim 1 wherein the transferable film composition on the carrier surface further comprises at least one acid catalyst. 
     
     
       3. The releasing carrier according to claim 1 wherein the transferable film composition on the carrier surface further comprises an antioxidant. 
     
     
       4. A decorative laminate prepared by the steps of: (A) stacking together in an assembly (a) one or more resin impregnated core sheets,   (b) a decorative fibrous sheet impregnated with a noble thermosetting resin, and   (c) a releasing carrier surface coated with a transferable film composition of polyvinyl butyral resin and melamine resin in contact with the decorative fibrous sheet;     (B) applying heat and pressure to consolidate the assembly into a unitary structure; and   (C) separating the releasing carrier surface from the unitary structure; the improvement wherein said transferable film composition reacts with the noble thermosetting resin of the decorative fibrous sheet during assembly consolidation.